Multi-channel plumbing products

ABSTRACT

Novel plumbing products, including faucets, are fabricated, e.g., using metallic 3-dimensional or other 3-D printing techniques, to have complex geometries, such as multiple channels that may diverge and re-converge near the spout. The geometries of the various channels can resemble interwoven net-like patterns that define various shapes between the channels. The plumbing fixtures may be formed from one or more of stainless steels, INCONEL, brass, bronze, polycarbonate, PVC, acrylics, rigid polyolefins, PET, carbon fiber, AES, or other plumbing fitting suitable corrosion resistant materials. In some embodiments, the handles of an exemplary faucet can include the same or a similar multiple channel configuration as the spout, providing an advantageously, aesthetically pleasing faucet system. In exemplary embodiments, faucet spouts and their handles are formed so as to couple to standard faucet underbodies, standard valve platforms, or standard threaded hose/waterway connections.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/140,480, filed Sep. 24, 2018, which is a divisional of U.S. patentapplication Ser. No. 14/850,561, filed Sep. 10, 2015, now U.S. Pat. No.10,106,962, which claims the benefit of U.S. Provisional PatentApplication No. 62/048,678, filed Sep. 10, 2014, the entire contents ofeach of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to faucets and like plumbingproducts, and in particular to novel plumbing products having complexgeometries, including convergent and divergent channels, that can befabricated using 3-dimensional printing techniques.

BACKGROUND OF THE INVENTION

Faucets are ubiquitous plumbing products having the basic purpose ofdelivering hot, cold or mixed water from a water supply to a user.Important performance factors of faucets include control of temperatureand flow rate, longevity, and absence of leaks, but the faucet has alsobecome an aesthetic showpiece in the decor of a living space, andespecially so in a lavatory application. Purchase decisions for lavatoryfaucets are often made purely on aesthetic design, and the choice oflavatory faucet is often the first decision made in the design of abathroom. Purchase decisions for other fixtures, fittings, furniture,and accessories (e.g., shower and tub fittings, etc.) are often dictatedby the choice of faucet. Thus, the capability to economically producenew, attractive, previously infeasible complex geometries offers asignificant competitive advantage in the marketplace.

Conventional faucet fabrication techniques are extremely limited inconstruction possibilities. Geometries must be amenable to castingprocesses. That is, geometries are limited to those that can be readilymolded and de-molded from a mold. Geometries with multiple undercuts,internal openings or spaces, multiple, small diameter channels, or thelike are not possible to form via conventional processes.

What is therefore needed in the art are techniques to leverage cuttingedge fabrication processes to expand, and preferably greatly expand, thefaucet geometries that can be fabricated.

What is further needed in the art is a palette of new faucet and faucetcomponent constructions that include structurally sound geometries withmultiple undercuts, internal openings or spaces, multiple, smalldiameter channels, in various unique combinations.

SUMMARY OF THE INVENTION

Generally speaking, novel plumbing products, including faucets, arefabricated, e.g., using metallic 3-dimensional or other 3-dimensionalprinting techniques, to have complex geometries, such as multiplechannels that may diverge and re-converge near the spout. The geometriesof the various channels can resemble interwoven net-like patterns thatdefine various shapes between the channels, such as a lattice-typefaucet defining parallelograms, circles or ovals, or multiple channelsdefining ellipses or half ellipses as channels diverge and thenre-converge. Other embodiments may have fewer channels that diverge atthe base of a faucet and re-converge at some distance above, afterdefining various curved paths at some defined convex curvature.

For example, the geometries of the channels can resemble interwovennet-like patterns. In another embodiment, the handles of an exemplaryfaucet can also include the same or a similar configuration as thespout, providing an advantageously, aesthetically pleasing faucetsystem.

The plumbing fixtures may be formed from one or more of stainlesssteels, INCONEL, brass, bronze, polycarbonate, PVC, acrylics, rigidpolyolefins, PET, carbon fiber, AES, or other plumbing fitting suitablecorrosion resistant materials. In some embodiments, the handles of anexemplary faucet can include the same or a similar multiple channelconfiguration as the spout, providing an advantageously, aestheticallypleasing faucet system. In exemplary embodiments, faucet spouts andtheir handles are formed so as to couple to standard faucet underbodies,standard valve platforms, or standard threaded hose/waterwayconnections.

Still other objects and advantages of the present invention will in partbe obvious and will in part be apparent from the disclosure.

The present invention accordingly comprises the features ofconstruction, combination of elements, arrangement of parts, and thevarious steps and the relation of one or more of such steps with respectto each of the others, all as exemplified in the constructions hereinset forth, and the scope of the invention will be indicated in theclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the inventive embodiments, reference ishad to the following description taken in connection with theaccompanying drawings in which:

FIGS. 1a-1c depict side, front and perspective views, respectively, ofan exemplary faucet handle according to an embodiment of the presentinvention;

FIGS. 2a-2c depict side, front and perspective views, respectively, ofan exemplary faucet spout according to an embodiment of the presentinvention;

FIG. 3 is a cross-sectional view of an exemplary faucet spout mountingfor the faucet spout of FIGS. 2a-2c according to an embodiment of thepresent invention;

FIG. 4 is a cross-sectional view of the handle mounting for theexemplary handles of FIGS. 1a-1c according to an embodiment of thepresent invention;

FIG. 5a is a bottom view of the exemplary spout of FIG. 2b showingdetail of the water chamber and waterways;

FIG. 5b is a cross-sectional side view of the exemplary spout of FIG. 2bshowing detail of the waterways leading to the spout end;

FIG. 6 shows front views of an alternate faucet system (spout andhandles) according to an exemplary embodiment of the present invention,including below-deck connections and a partial cross-sectional view of aportion of the waterways;

FIG. 7 is a partial side view of the spout of FIG. 6 along section 7-7ofFIG. 6;

FIG. 8a shows front views of alternate faucet components according to anexemplary embodiment of the present invention, including below-deckconnections and a partial cross-sectional view of the faucet body;

FIG. 8b is a side view of the faucet system of FIG. 8 a;

FIG. 9a depicts detail of below-deck connections for the exemplaryfaucet system (spout and handles) of FIGS. 1a-1c and 2a -2 c;

FIG. 9b is a side view of the faucet system of FIG. 9 a;

FIGS. 10a-10e depict bottom, side, front and top views of an alternativefaucet system according to an embodiment of the present inventionsimilar to the embodiment shown in FIGS. 8a and 8 b;

FIGS. 11a-11e depict bottom, side, front and top views of anotherexemplary multi-channel faucet system according to an embodiment of thepresent invention;

FIGS. 12a is an exploded view of a variation of the faucet system ofFIGS. 9a and 9b , where the handles echo the lattice construction of thespout;

FIG. 12b is a front view of the faucet system of FIG. 12a including apartial cross-sectional view of the spout and a handle;

FIG. 12c is a cross-sectional side view of the spout of FIG. 12b ; and

FIGS. 13a-13e respectively depict bottom, side, front and top views ofthe exemplary faucet system of FIGS. 12a -12 c.

DETAILED DESCRIPTION OF THE INVENTION

Exemplary embodiments of the present invention leverage advances in3-dimensional (“3-D”) printing. It is noted that metallic and multimedia3-D printing are relatively recent, cutting-edge processes, which arenow used in many industrial applications, including the manufacture ofjet engine parts and surgical implants. The present inventors havediscovered that 3-D printing of plumbing fixture components,particularly faucet components, can be utilized to produce complexgeometries not achievable by conventional plumbing fixture casting orother fabrication technologies, forging, stamping, die-casting, etc. 3-Dprinting can also be leveraged as an economical manufacturing strategyfor low volume plumbing fixture models, such as specialized or customconstructions. Component geometries that are feasible to produce byconventional approaches can also be produced by 3-D printing, whicheliminates tooling and start-up costs, making production runs of limitedquantities more economical.

Complex and aesthetically interesting plumbing fixtures, particularlyfaucet spouts and handles, can be produced by 3-D printing. The faucetcomponents (handles and spout) can be formed so as to couple to standardfaucet underbodies, standard valve platforms, and standard threaded (orother) hose/waterway connections. That is, since no real changes toother components of the faucet are required, the new fixtures can beused with existing valving and mounting fixations.

Some of the spout embodiments contain multiple channels through whichwater can diverge from a common inlet at the base of the faucet andconverge near the outlet of the faucet before an optional aerator.Faucets with such divergent and convergent water channels can providecomplex geometries such as, for example, interwoven net-like patternsthat would be impossible to produce via conventional processes. As themixed water can be fed through multiple channels, the cross-sectionalarea of each segment can be relatively small and still provide foracceptable flow rates through the faucet.

In exemplary embodiments according to the present invention, various 3-Dprinting techniques may be used. For example, for all metal plumbingproducts, direct metal laser sintering may be used, as described, forexample, here: http://www.atlanticprecision.com/dmls/, or for example,Electron Beam Additive Manufacturing (EBAM) Technology, as described,for example, herehttp://www.sciakyl.com/additive-manufacturing/electron-beam-additive-manufacturing-technology.Other techniques and processes may be used as may be desirable oruseful. Additionally, non-metallic, and mixed metallic materials andfeed-stocks may alternatively be used, as described below. With suchmaterials, in some embodiments, a stereo-lithography, or SLA process,may be used.

In one embodiment, using direct metal laser sintering, the channels canbe created during the 3-D printing process by selective sintering of theouter walls. The fabrication process can include provision of suitablecontrols and/or parameters, such as, for example, for the sinteringprocess, to adjust for design requirements, such as temperature, anglesof the various geometric structures, etc. For example, for the exemplaryfaucet spout of FIGS. 2a-2c , made by the inventors hereof using adirect metal laser sintering process, in some embodiments, the multiplechannels making up the lattice should slant upwards form the horizontalat an angle of at least 45 degrees. If flatter angles are used, thefaucet spout can collapse on itself while being fabricated. It is notedthat such parameters are generally process dependent. The angles usedare thus imposed by constraints of the actual 3-D printer, or 3-Dprinting process, and not the support requirements of the plumbingproduct itself. It is also noted, however, that even in an exemplary 3-Dprinting process using direct metal laser sintering used by theinventors to create the faucets of FIGS. 2a-2c and 12, by changing theorientation of the plumbing product in the machine, one can createconstructions having angles with the horizontal that are smaller than 45degrees.

Thus, in other 3-D fabrication processes, for example, differentconstraints may be imposed, and different parameters for the 3-Dprinting possible. For example, in the EBAM or SLA technologiesdescribed above, these angular minima may not be operative.

In exemplary embodiments of the present invention wherein a direct metallaser sintering process is used, remaining non-sintered metallic powderfrom the 3-D printing process can be removed as a post-treatment with astream of pressurized fluid. Internal channels can, for example, befurther treated and/or cleared with acid etching and/or abrasiveslurries. Preferred materials for 3-D printing are stainless steels,INCONEL, brass, bronze, or other application-suitable corrosionresistant materials.

In exemplary embodiments of the present invention, there will be limitson the cross-sectional area (or diameter) of a given channel, and alsoon the aggregate cross-sectional area of all of the multiple channels,in a given plumbing product. These limits are a function of assumedoperating pressure, and number of channels overall. For example, inplumbing products with several multiple channels, such as are shown, forexample, in FIGS. 2a-2c and 6-13, (i) the cross-sectional area of anyone channel should have at least an average 1 mm diameter (it beingnoted that the cross-sectional areas of the water channels need not be,and in general are not, perfect circles), and (ii) the aggregatecross-sectional area of all of the individual channels should not beless than about 7 or 8 mm². In some embodiments, to allow for pressurevariation and possible long term buildup of sludge on the inside ofwater channels, the aggregate cross-sectional area of all of theindividual channels may be set at not less than about 12 mm², to ensurea margin of error.

Further parameters may be imposed by the 3-D printing process used.Thus, where a sintering process is used, the channel inner diameter mustbe such to as to be able to remove excess powder. Thus, in someembodiments a minimum average diameter of about 3-4 mm may be set. Inother processes, such as, for example, an SLA process, where there is nopowder to remove after fabrication (only wax which can easily be meltedaway), such minima are not necessary, and only considerations of minimumaverage diameter for water flow are of concern, as described above.

As noted above, a plumbing fixture need not be restricted to metals, orin fact, to any one material. It is understood that any suitablematerial, or combination of materials, that can be used as the feedstockfor a 3-D printer that can harden may be used. These materials mayinclude, for example, polycarbonate, PVC, acrylics, rigid polyolefins,PET, carbon fiber, AES, etc., where a non-metallic plumbing product isneeded or desired.

Additionally, multi-media 3-D printing is now becoming a workabletechnology. Thus, in some embodiments, mixed metallic-plastic items,using various combinations of metals and transparent plastics may befabricated using the disclosed techniques. For example, in someembodiments a plastic water channel may be used, which is plated on theoutside for aesthetic reasons with a metal, such as chrome or nickel,for example. Or, for example, the inner channel which the water contactsmay be metallic, and the metallic channel surrounded by a plastic ortransparent sleeve.

In exemplary embodiments of the present invention, spouts and handlescan be post-processed using many of the same techniques used forfinishing the cast brass components used in conventional faucetproduction. Water supply connections and waterways can be attached bymachining threads or other connection fittings (e.g., direct sweatedcopper pipe). Surfaces can be buffed, polished, chrome plated, PVDplated, powder coated, etc. In products made of metals, the use ofhighly corrosion resistant alloys such as stainless steels and INCONELallows for attractive, aesthetically pleasing finishes to be obtained bysimple buffing and polishing of the printed surface. As current 3-Dprinting technologies can produce metal parts at greater than 99%theoretical density, such polished components will be relatively free ofsurface irregularities and have an aesthetic appearance similar to thatof conventionally processed faucets finished with chrome plating.Selective buffing and polishing of certain features on the faucet spotand handle can be used to create a two-tone effect, which can bedesirable in some constructions.

Accordingly, 3-D printing processes can be leveraged to fabricatefaucets, particularly faucet components, embodying novel intricategeometric features that can include multiple water channels (e.g.,convergent and/or divergent) that would otherwise be impossible to formvia conventional methods. Different channel angles and sizes can bespecified to create various novel, structurally sound, constructions.

It should be understood that the multi-channel faucet geometries can bedefined by the spout itself—no tubes or the like encased in sleeves, oreven central piping, for example, are necessary or desirable.

It should be appreciated that, in addition to fabricating faucets, 3-Dprinting can also be leveraged to fabricate other metallic fittings,embodying complex geometries conventionally unrealizable, such as triplevers for toilets, knobs for cabinetry, bath fittings, shower heads,etc.

As noted above, to successfully create functional water passages forfaucets using metal 3-D printing technology, the water passage should besufficiently unobstructed to allow water flow. Thus, in exemplaryembodiments of the present invention, the following minimum geometryparameters should be adhered to:

-   -   1. water passages should be reasonably clear of any support        structure and material, including any residual material from the        operative 3-D printing process;    -   2. unsupported connecting angles of the water passages should be        optimized for structural integrity—e.g., to reduce the number of        supports needed for printing;    -   3. water passage cross-sectional areas in the aggregate should        be at least about 7 mm²; and    -   4. each individual water passage should have an average diameter        of about at least 1 mm in diameter.

If the plumbing product is to be used with a pressure booster, or in abuilding or installation where internal water pressure is boosted, andone need not assume only municipal water pressure is available, then theparameters 3 and 4 may be further relaxed, as appropriate, given theactual driving pressure of the faucet.

Next described are the various figures and the exemplary constructionsand features they illustrate and embody.

FIGS. 1a-1c depict a faucet handle 100 according to an embodiment of thepresent invention; and FIGS. 2a-2c depict a matching faucet spout 200.This is an exemplary lattice type construction, where multiple channelsdiverge and converge to define a diamond-like shape. In otherembodiments, the corners of that shape may be rounded, or the shapeitself a circle, ellipse, or the like. The matching handles may includea scaled down version of the shape defined in the lattice, itself usingmultiple channels, or it may echo the lattice defined shape in lessidentical ways.

FIG. 3 depicts an exemplary faucet spout mounting 250 for the faucetspout of FIGS. 2a -2 c.

FIG. 4 is a cross-sectional view of the handle mounting 275 for theexemplary handles of FIGS. 1a -1 c.

FIG. 5a is a bottom view of spout 200 of FIG. 2b , showing the waterchamber and waterways detail; and FIG. 5b illustrates a side view ofspout 200 showing detail of the waterways leading to the spout end. Invariant embodiments, the multiple channels may converge at the end, nearthe actual exit point of the water, as may be desired. As is noted withreference to FIGS. 2a-2c and 5a-5b , the shapes defined by the latticecan become progressively smaller towards the distal end of the spout, asthe multiple channels necessarily are now closer to each other as theydefine the spout tubular shape. This is to preserve the cross-sectionalarea of the actual channels to maintain unobstructed flow.

FIG. 6 illustrates an alternate faucet 600 according to an exemplaryembodiment of the present invention, including the faucet connectionsthat are provided below the faucet deck. Here, the channels divergeonce, and then re-converge above, in a “bow” shape. Thus, the twochannels are much larger in diameter than, for example, the multiplechannels of the embodiment of FIGS. 1a-1c and 2a-2c . FIG. 7 is apartial side view of the spout of faucet 600 of FIG. 6.

FIG. 8a illustrates a further alternate faucet 800 according to anexemplary embodiment of the present invention, including the below-deckconnections; and FIG. 8b depicts a side view of faucet 800. Here, thereare four channels that diverge at the bottom of the faucet, and theneach protrudes upwardly along a defined radius of curvature, andre-converge at the top. This construction may be modified in variousways, such as by varying the radius of curvature, the number of arms orchannels, and the ultimate height of the multiple channel portion of thefaucet.

Jumping now to FIGS. 10a-10c , these depict, with respect to the faucethandles, a variation (faucet 1000) of the faucet shown in FIGS. 8a and 8b.

Turning now to FIG. 9a , detail is provided of the below-deckconnections for an exemplary faucet 900, including spout 200 and handles100 of FIGS. 1a-1c and 2a-2c ; and FIG. 9b is a side view of faucet 900of FIG. 9 a.

FIGS. 11a-11c illustrate yet another multiple channel faucet 1100—here,with the multiple channels running essentially in parallel to create a“bundle” appearance, as the base of a waterfall type faucet that ejectswater so that it rises vertically, and then descends in a parabolatrajectory.

FIGS. 12a-12c depict various views of a faucet 1200 that is a variationof faucet 900. Here, the handles echo the lattice of the spout.

Finally, FIGS. 13a-13c depict additional views of faucet 1200.

It will thus be seen that the aspects, features and advantages madeapparent from the foregoing are efficiently attained and, since certainchanges may be made without departing from the spirit and scope of theinvention, it is intended that all matter contained herein shall beinterpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed and all statements of the scope of the invention that, as amatter of language, might be said to fall therebetween.

1. A faucet, comprising: a water chamber; a plurality of water channelsfluidly connected to the water chamber, wherein: each of a plurality ofwater channels is configured to transport water from a respective waterinlet proximate to the water chamber to a respective water outlet, andeach of the plurality of water channels is configured to output waterinto a single combined water stream.
 2. The faucet of claim 1, whereinat least one of the plurality of water channels extends upward from thewater chamber.
 3. The faucet of claim 1, wherein the plurality of waterchannels forms a base portion of the faucet that extends upward from thewater chamber, the plurality of water channels configured to transportwater upward from the respective water inlets through the base portion.4. The faucet of claim 1, wherein the plurality of water channels formsa spout portion of the faucet that extends downward toward therespective water outlets, the plurality of water channels configured totransport water downward through the spout portion toward the respectivewater outlets.
 5. The faucet of claim 4, wherein: a first channel of theplurality of channels terminates, at its respective water outlet, in thespout portion of the faucet, at a first vertical height, and a secondchannel of the plurality of channels terminates, at its respective wateroutlet, in the spout portion of the faucet, at a second vertical heightlower than the first vertical height.
 6. The faucet of claim 5, thefirst channel and second channel are configured such that waterdispensed from the outlet of the first channel flows over and along anupper surface of an outer wall of the second channel.
 7. The faucet ofclaim 4, wherein the spout portion of the faucet comprises a parabolicarc shape.
 8. The faucet of claim 1, wherein each of the plurality ofwater channels comprises a respective exterior surface extending aroundthe respective water channel and forming a respective tubular structure.9. The faucet of claim 8, the respective exterior surfaces of each ofthe plurality of water channels are spaced apart from one another. 10.The faucet of claim 1, wherein a third water channel of the plurality ofwater channels converges with and re-diverges from a fourth waterchannel of the plurality of water channels, thereby forming a firstintersection located between the respective water inlets and therespective water outlets of the third and fourth water channels.
 11. Thefaucet of claim 10, wherein the third water channel of the plurality ofwater channels converges with and re-diverges from a fifth water channelof the plurality of water channels, thereby forming an secondintersection, distinct from the first intersection, located between therespective water inlets and the water outlets of the third and fifthwater channels.
 12. The faucet of claim 1, wherein a cross-sectionalarea of all of the plurality of water channels in aggregate is greaterthan or equal to about 7 mm².
 13. The faucet of claim 1, wherein theaverage diameter of the plurality of water channels is greater than orequal to about 1 mm.
 14. The faucet of claim 1, wherein the componentsof the faucet are formed so as to couple to standard faucet underbodies,standard valve platforms, or standard threaded hose/waterwayconnections.
 15. The faucet of claim 1, wherein the plurality of waterchannels comprise six water channels.
 16. The faucet of claim 1, whereinthe plurality of water channels are collectively formed as a unitarymetal component.
 17. The faucet of claim 1, wherein the faucet is formedof one or more of stainless steels, INCONEL, brass, or bronze, bymetallic 3-D printing.
 18. The faucet of claim 17, wherein the faucet isformed by selective sintering of the outer walls of one or more of thechannels.